JP2014157606A - Plastic layer for smart card - Google Patents

Abstract

PROBLEM TO BE SOLVED: To solve the problem of a conventional technology by improving a smart card manufacturing method.SOLUTION: A plastic sheet 22 required for manufacturing of a plurality of smart cards respectively including a plurality of electronic units is made from first materials 2 having a first hardness or a first Vicat softening temperature and second materials 6 having a second hardness lower than the first hardness or a second Vicat softening temperature lower than the first Vicat softening temperature. The second materials are positioned in a plurality of areas of the plastic sheet, and each of the plurality of areas at least partially receives the plurality of electronic units by inserting the plurality of electronic units into the second material during manufacturing of the plurality of smart cards.

Description

  The present invention relates to the field of smart cards that incorporate at least one electronic unit, specifically an integrated circuit, inside the card body. More particularly, the present invention relates to a plastic material that forms a card body. The invention also relates to a method of making a plastic layer intended to receive a plurality of electronic units while forming a plurality of cards.

  An assembly formed from integrated circuits and a method of making a smart card in which a conductive segment is placed on a substrate and at least one integrated circuit is introduced into the substrate are specifically known from EP 1 844 874. is there. Several variants have also been proposed. In the first embodiment, the integrated circuit is pushed directly into the material forming the substrate. This material is relatively hard because it has a conductive path on its surface. Insertion into the material is generally accomplished by using heat to at least locally soften the substrate material. In a second embodiment, prior to inserting the integrated circuit, a housing having a dimension substantially matching or slightly different from the dimension of the integrated circuit is placed on the substrate. In a third embodiment, a housing having a dimension that is larger than the dimensions of the integrated circuit is formed, adhesive material is applied to the housing prior to adding the integrated circuit assembly and the conductive segments, and then the integrated circuit by the mounting device. Is pushed into the adhesive substance. This adhesive material spreads into the space located between the integrated circuit and the wall of the housing and is pushed into the back.

  Each of the embodiments described above can be realized but has drawbacks. In the first embodiment, the substrate is formed entirely by a relatively hard plastic layer, which requires special attention during the manufacture of the smart card, in particular at least locally in the area through which the integrated circuit is inserted. Face the fact that it needs to be softened to avoid damage to the integrated circuit. Furthermore, after finishing the card, the integrated circuit is surrounded by a relatively hard material. This can cause excessive mechanical stress on the integrated circuit during use of the card, particularly if the card is bent or twisted. In addition to the problems mentioned at the end of the first embodiment, the second embodiment is made because the integrated circuit needs to be positioned with high precision relative to the housing before the integrated circuit is inserted into the housing. Cause problems. This can be achieved using available production factories, but the production of smart cards is more expensive. Although the third embodiment can overcome some of the above-mentioned problems, it is necessary to locally apply resin to the substrate housing at the smart card fabrication site in droplets.

  One object of the present invention is to overcome the above-mentioned problems of the prior art and to improve the smart card manufacturing method.

  Accordingly, the present invention relates to a plastic sheet required for forming a plurality of smart cards each including a plurality of electronic units. The plastic sheet has a first material having a first hardness or a first Vicat softening temperature, a second material having a second hardness lower than the first hardness and lower than the first Vicat softening temperature. Formed from a second material having a Vicat softening temperature of 2. The second material is located in a plurality of regions of the plastic sheet, each of which is intended to receive at least partly by inserting a plurality of electronic units through the second material.

  The present invention also relates to a plastic sheet manufacturing method according to the present invention, which will also be described below.

  The present invention will be described below with reference to the embodiments shown in the drawings.

FIG. 2 is a schematic illustration of one step of the method of the present invention for making a bimaterial plastic sheet. It is a schematic sectional drawing explaining the next step of the preparation methods by this invention. It is a schematic sectional drawing explaining the next step of the preparation methods by this invention. It is a schematic sectional drawing which shows 1st Embodiment of the bimaterial plastic sheet by this invention. It is the schematic which shows 2nd Embodiment of the bimaterial plastic sheet by this invention. It is the schematic explaining 3rd Embodiment of the bimaterial plastic sheet by this invention. It is a schematic top view explaining 4th Embodiment of the bimaterial plastic sheet by this invention. It is the schematic explaining one usage method of the bimaterial sheet | seat by this invention in the 1st preparation method of a smart card. FIG. 9 is an intermediate product obtained from the steps of FIG. 8 using a first method of making a smart card. It is the schematic of one usage of the bimaterial sheet | seat by this invention using the 2nd preparation method of a smart card. It is a figure explaining the 2nd manufacturing method of a smart card, Comprising: It is an intermediate product obtained from the step shown in FIG.

  First, one method for producing a plastic sheet necessary for forming a plurality of smart cards each including a plurality of electronic units will be described. The plastic sheet is intended to at least partially receive a plurality of electronic units by inserting the material forming the unit, as will be described below.

The method for producing a plastic sheet according to the present invention includes:
A) A step of preparing a first sheet 2 formed of a first material having a first hardness or a first Vicat softening temperature, and a step of providing a plurality of openings 4 in the first sheet (FIG. 1);
B) A plurality of disks 6 made of a second material having a second hardness lower than the first hardness or a second Vicat softening temperature lower than the first Vicat softening temperature are respectively placed in the plurality of openings 4. Including the placing step (see FIGS. 1 and 2; for the sake of clarity, FIG. 1 shows only the disks provided in a row of openings).

  In some embodiments, the first sheet has a plurality of cavities (blind holes) and the disk is placed in the plurality of cavities. In another embodiment, the first sheet has openings (through the first sheet) and cavities that receive all the disks formed from the second material, the openings and cavities being the first Arranged to receive each of the electronic unit and the second electronic unit.

  In the shape plane parallel to the entire surface 10 of the first sheet 2, the plurality of discs 6 provided in step B) above have a diameter smaller than the diameter of the corresponding opening 4 and / or cavity, and Along the axis perpendicular to the whole surface, the plurality of disks 6 have a height H that exceeds the height of the corresponding openings and / or cavities so that they protrude above the surface 8 of the first sheet. For circular disks, the diameter D of these circular disks will be smaller than the diameter of the corresponding opening 4 and / or cavity. For rectangular discs, of course, the width and length of the rectangular disc are smaller dimensions. As another example, other disk shapes may be provided on the entire surface 10.

  Preferably, the first sheet 2 and the disk 6 are placed on a support 12 having an upper layer 14 that is non-adhesive to the first sheet and disk. The upper layer 14 is made of, for example, Teflon (registered trademark), and the support 12 forms a part of the press 16 schematically shown in FIG.

After inserting each disc 6 into the corresponding opening 4 or cavity,
C) Pressure is applied to the disk 6 such that the disk is substantially flush with the surface 8 of the first sheet 2 and at least partially in contact with the corresponding opening or cavity sidewall 20. A step of reducing the height is applied, whereby the disk 6 is connected to the first sheet.

  In the first embodiment shown in FIG. 3, step C) is performed using a laminating press 16. The bottom surface of the upper press is formed by a layer of Teflon® 18 if possible. Note that layers 14 and 18 may be replaced with removable non-stick sheets. As a preferred embodiment, step C) consists of hot laminating, in which a plurality of disks 6 are at least partially welded to the first sheet 2. The press 16 then includes heating means. In this first implementation, a set of disks is placed in the corresponding opening and then step C) described above is performed simultaneously on a plurality of disks. In a second implementation (not shown), steps B) and C) are performed in a circulating manner on each disk or a subset of the disks. In the first embodiment, each disk is individually placed in the corresponding opening using a tool. Next, the thermo mode is individually applied to the disk to perform step C). These two steps are repeated on the next disc. Preferably, the dimensions of the thermode are slightly larger than the dimensions of the openings. Therefore, the thermode covers the opening and the peripheral area of the opening when the disk inserted into the opening is pushed. For this reason, this can be referred to as local laminating. In a particular embodiment, the first tool and the thermode form the same tool, and step C) immediately follows step B) on each disk. In a second embodiment, the first subset of disks is placed in a corresponding opening in the first subset. Next, several thermo modes are respectively placed on the subset disks and step C) of the method is performed simultaneously on the subset disks. The subset of openings is, for example, one row or one row of openings in the first sheet having matrix-like openings.

  In particular, a first embodiment of the bimaterial plastic sheet 22 according to the present invention obtained by the above-described production method is shown in cross section in FIG. The plastic sheet is formed from a first sheet 2 formed from a first material having a first hardness. The first sheet 2 has a plurality of openings, which are loaded by a disk 6 formed from a second material having a second hardness lower than the first hardness described above. The second material adheres to the sidewall 20 of the hole. The plurality of openings 4 define a plurality of regions 5 of the plastic sheet 22 in which the second material is located. Each of these lower hardness regions is intended to receive a plurality of electronic units by inserting a second material, as described below.

  In the first embodiment, the second hardness is Shore A of less than 96. In the second embodiment, the first hardness is Shore D greater than 60. As a specific example, the first and second embodiments can be advantageously combined. Preferably, the second material is formed by a thermoplastic polyurethane elastomer. For the definition of ShoreA and ShoreD, reference can be made to ISO standard 868 and DIN standard 53505, respectively. The thermoplastic polyurethane elastomer is specifically sold by the company BASF under the name Elastollan®.

According to another embodiment of the present invention, the plastic sheet used in the present invention comprises a first material 2 having a first Vicat softening temperature and a second Vicat softening temperature lower than the first Vicat softening temperature. It is formed from the 2nd material 6 which has these. In the first embodiment, the second Vicat softening temperature under a load of 10 N is less than 50 degrees (50 ° C.). In the second embodiment, the first Vicat softening temperature under a load of 10 N exceeds 65 degrees (65 ° C.). Also, in other embodiments, the first embodiment and the second embodiment can be advantageously combined. Preferably, the second material is formed by a thermoplastic polyurethane elastomer. The Vicat softening temperature is a temperature reference that allows a pin having a cross section of 1 mm ² to pass through a thermoplastic material to a depth of 1 mm when inspected under a load of 10 N or 50 N (see ISO 306 for more information) can do). Various embodiments of the plastic sheet of the present invention also apply to this alternative.

  A second embodiment of the bimaterial plastic sheet 24 according to the invention is shown in cross section in FIG. The plastic sheet 24 is formed in that the plastic sheet 24 is formed from a first sheet 2A formed from the first material, and has a plurality of cavities 26 loaded with disks 6A formed from the second material. Different from the first embodiment. The plurality of cavities 26 open in the upper surface 8 of the plastic sheet 24 and define a plurality of regions 5A in which the second material is located. The plurality of regions of lower hardness are each intended to receive a plurality of electronic units by inserting a second material as described below. It is noted that in other embodiments, the first sheet 2A is formed by two layers 28 and 29, where layer 28 has a plurality of holes, while layer 29 is continuous and defines the bottom of cavity 26. I want. Layers 28 and 29 may be welded or joined in a pre-step prior to inserting the plurality of disks 6A. Preferably, layers 28 and 29 are welded simultaneously with pushing and welding the disk 6A into the first sheet 2A during step C) of the production method described above.

  As another example, it should be noted that the disk 6 or the disk 6A can be joined inside the opening 4 or the cavity 26, respectively. In another embodiment, the second material is introduced into the opening 4 or cavity 26 by a technique of injecting or casting the second material.

  A third embodiment of the bimaterial plastic sheet 32 according to the invention is shown in cross section in FIG. The third embodiment differs from the above-described embodiment in that the plurality of openings 4B of the first sheet 2B each have an annular shoulder 34 at the bottom thereof. The disc 6B has an initial diameter such that it abuts against the side wall 20B of each shoulder 34 during the pushing in performed in step C) of the fabrication method described above, but on the annular shoulder The annular region 35 located is not loaded. The disc 6B defines a lower hardness region 5B on the upper surface 8 of the plastic sheet 32 having a diameter smaller than the diameter of the respective opening 4B. The space remaining in each annular region 35 is advantageous for subsequent insertion of the electronic unit, specifically when the unit has a relatively large size and the second material forming the disk 6B is not compressible. is there. Finally, as in the second embodiment, the first sheet 2B is formed of two preferred layers 36 and 37, each having a first plurality of holes and a second plurality of holes, Note that the second plurality of holes has a smaller diameter than the diameter of the first plurality of holes. These two layers 36 and 37 are preferably hot laminated in a pre-step before inserting the disc 6B into the opening 4B.

  When the cavities are provided in the first plastic sheet, it is possible to provide disks having dimensions such that the disks do not contact the cavity sidewalls, the connection between these disks and the first sheet being at the bottom of the cavity. Note that Therefore, it is possible to leave a circular space (empty space) inside the cavity around the disk.

  FIG. 7 shows a fourth embodiment of the bimaterial plastic sheet 40 according to the present invention. The fourth embodiment is different in that the disk 6C inserted into the opening 4 of the first sheet 2 has a side surface different from the outline of the corresponding opening on the entire surface of the first sheet. In the production method described above, the initial side surface of the disc 6C is selected so that the protruding portion of the disc contacts the corresponding side wall 20 of the opening 4 during step C) of the method while leaving an empty area 39 in the opening. To do. During the last pushing of the disc 6C, the protruding part is slightly deformed by the pressure exerted on the protruding part by the side wall 20 and this protruding part eventually adheres to the first material forming the first sheet 2. . In an embodiment, a slight amount of heat is applied to deform the disk, ensuring that the disk is connected to the first sheet. It should be noted that it is also possible to provide at least one recess in the disc, in particular in the central area of the disc. Preferably, this recess is made according to one or more electronic units to be inserted into the corresponding openings. For example, the recess is positioned in the area comprising the thinnest part of the electronic unit, or if several electronic units are inserted into the same opening of the first sheet 2, the recess will be the thinnest electronic unit. It will be positioned in the area to be provided. In this embodiment, the most fragile part of the electronic unit to be used or the most fragile electronic unit among the electronic units is positioned in the region of the recess.

  FIG. 8 shows a schematic diagram of one usage of the plastic sheet 22A according to the present invention in the first method for producing a smart card. The plastic sheet 22A is placed on the support 12A. The plastic sheet is the same as the plastic sheet 22 described above, and an electronic circuit disposed on the upper surface 8 is added. At the periphery of each region 5 defined by the low hardness disk 6, the electronic circuit includes contact pads 44 for electrical connection to an electronic unit 46. The electronic unit 46 and the conductive segment 48 are moved onto the plastic sheet 22A using the gripping tool 50 so that the electronic unit is located on the disk 6. Next, the assembly formed from the electronic unit by the gripping tool and the conductive segment are lowered toward the disk 6 and the electronic unit 46 is inserted into a relatively soft material forming the disk. Therefore, the electronic unit easily inserts the plastic sheet according to the present invention. In this embodiment, the material forming the disk 6 is compressible. In that case, an intermediate product 52 shown in cross section in FIG. 9 is obtained. The material of the disk 6 is compressed or in a compressed state. In another embodiment, particularly in small-sized integrated circuits, the material forming the disk 6 slightly exits the opening when the electronic unit is inserted through the opening 4. This partially covers the top surface of the integrated circuit and causes electrical problems that later occur between the integrated circuit and the conductive segment 48 that must have electrical contacts only with one determined pad of the integrated circuit. It is possible to avoid if there is. In another embodiment, the disk 6 has a lower Vicat softening temperature and insertion of the electronic unit 46 into the disk deforms the first sheet 2 by applying heat to soften the disk quickly. Without the risk of damaging the electronic unit.

  FIG. 10 is a schematic view of one usage of the plastic sheet 56 according to the present invention in the second method for producing a smart card. The plastic sheet 56 is formed by the above-described plastic sheet 32 and a continuous plastic film 58 that closes the opening 4B on the back side of the plastic sheet 32. Note that the opening 4B defines a plurality of cavities in the plastic sheet 56. The printed circuit 54 having the electronic unit 46 </ b> A disposed on the upper surface is placed on the support 12. A plastic sheet 56 is placed opposite the printed circuit 54 and is deposited on the printed circuit so that the electronic unit is placed facing the disk 6B. Next, using a press, the electronic unit is inserted into the cavity 4B through which the material forming the disk 6B is inserted. During this insertion, the disk 6B is deformed so that at least substantially the annular region 35 is loaded by shifting the material of the disk to substantially reduce the space originally in the cavity 4B. The smart card 60 shown in section in FIG. 11 is thus obtained.

Claims (12)

  In a plastic sheet (22, 24, 32, 40, 22A, 56) for manufacturing a plurality of smart cards, each including a plurality of electronic units (46, 46A), the plastic sheet has a first hardness or a second hardness. A first material having a Vicat softening temperature of 1; a second hardness lower than the first hardness; and a second material having a second Vicat softening temperature lower than the first Vicat softening temperature. The formed second material is located in a plurality of regions (5, 5A, 5B, 5C) of the plastic sheet, and each of the plurality of regions (5, 5A, 5B, 5C) is the plurality of electrons. Plastic sheets (22, 24) characterized in that the plurality of electronic units are at least partially received by inserting a unit through the second material. 32,40,22A, 56).   2. The plastic sheet according to claim 1, wherein the second Vicat softening temperature under a load of 10 N is less than 50 degrees (50 ° C.). 3.   2. The plastic sheet according to claim 1, wherein the second hardness is Shore A of less than 96. 3.   4. The plastic sheet according to claim 1, wherein the first Vicat softening temperature under a load of 10 N is less than 65 degrees (65 ° C.). 5.   4. The plastic sheet according to claim 1, wherein the first hardness is Shore D exceeding 60. 5.   The plastic sheet according to claim 1, wherein the second material is formed of a thermoplastic polyurethane elastomer.   The said first material forms a first sheet (2, 2B) having a plurality of openings (4, 4B) that are at least partially loaded by said second material. The plastic sheet according to any one of 1 to 6.   The first material (2A) according to claim 1 to 6, characterized in that the first material forms a first sheet (2A) having a plurality of cavities (26) that are at least partially loaded by the second material. The plastic sheet as described in any one of them. A method for producing plastic sheets (22, 24, 32, 40, 22A, 56), each of which is necessary for forming a plurality of smart cards each including a plurality of electronic units, wherein the plastic sheets form the sheets Accepting the plurality of electronic units at least partially by passing the plurality of electronic units through a material, the method comprising:
A) a first sheet (2, 2A, formed from a first material having a first hardness or a first Vicat softening temperature and having a plurality of openings (4, 4B) and / or cavities (26) Preparing 2B);
B) a plurality of discs (6, 6A, 6B, formed from a second material having a second hardness lower than the first hardness and a second Vicat softening temperature lower than the first Vicat softening temperature; 6C) in each of the plurality of openings and / or cavities, wherein the plurality of discs correspond to a shape surface parallel to the overall surface (10) of the first sheet and the corresponding openings and / or A diameter (D) that is smaller than the diameter of the cavity, and the corresponding openings and / or cavities so that the disc rises above the surface (8) of the first sheet along an axis perpendicular to the overall surface. Preparing to have a height (H) greater than the height of;
C) The disk is substantially flush with the surface (8) of the first sheet, and the side walls (20, 20B) of the plurality of openings and the side walls of the plurality of cavities. And / or reducing the height of each of the plurality of disks by applying pressure to each of the plurality of disks so as to at least partially contact the respective bottoms, whereby the plurality of disks are A method, characterized in that it is connected to the first sheet.   10. The manufacturing method according to claim 9, wherein the step B) and the step C) are performed by circulating each disk of the plurality of disks or a subset of the plurality of disks.   11. A method according to claim 9 or 10, characterized in that the step C) comprises hot pushing in at least partially welding the plurality of discs to the first sheet.   The manufacturing method according to claim 11, wherein the high-temperature indentation is performed individually for each of the plurality of disks using a thermode.

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